Manufacturing Cost Annual. California 2011 Data

Transcription

1 Manufacturing Cost Annual California 2011 Data

2 C A L I F O R N I A Manufacturing Cost Annual 2011 Data Table of Contents Manufacturing Cost Overview Introduction... 3 Manufacturing Cost Overview... 4 Butter This publication was prepared in the Division of Marketing Services, Dairy Marketing Branch, by: Manufacturing Cost Unit Staff: Venetta Reed, Supervisor Raymond Greth Jackie Juarez Leticia Regalado Joseph Reno Stephanie Qian Butter Study... 5 Butter Manufacturing Costs... 6 Nonfat Dry Milk Nonfat Dry Milk Study... 8 Nonfat Dry Milk Manufacturing Costs... 9 Cheese Cheese Study Cheese Manufacturing Costs Condensed Skim and Cream Special Thanks This publication would not be possible without the cooperation of the individuals and firms engaged in the production, manufacture, and distribution of milk and dairy products. Condensed Skim Overview Cream Overview Plant Flowchart Diagrams Butter and Nonfat Dry Milk Plant Cheese Plant California Department of Food and Agriculture Karen Ross, Secretary Dairy Marketing Branch 1220 N Street, Sacramento, CA (916) / Address: dairy@cdfa.ca.gov California Manufacturing Cost Annual - Page 2

3 Introduction The California Food and Agricultural Code specifies that the California Department of Food and Agriculture (CDFA) must consider manufacturing costs in determining appropriate minimum prices for products categorized as Class 4a (butter and dried milk products) and Class 4b (cheese). To comply with the legislative decree, CDFA has a direct need for gathering and summarizing information provided in the cost studies to formulate reasonable manufacturing cost (make) allowances through the public hearing process. CDFA maintains a Manufacturing Cost Unit that consists of professional auditors specializing in dairy accounting practices. The auditors work with plant management to gather data on all aspects of the operation, review plant records on-site, and allocate plant expenditures to each product manufactured by the plant. The studies are conducted and developed in conformity with generally accepted accounting principles, cost accounting techniques, and instructions contained in the Dairy Marketing Branch s Audit and Cost Procedures Manual. Any plant that produces Class 4a and/or Class 4b products may be asked to participate in the cost studies. Information gathered in the studies provides an accurate sampling of California s annual butter, nonfat dry milk (NFDM), and Cheddar cheese production. The 2011 California Manufacturing Cost Annual includes data obtained from eight butter plants, nine NFDM plants, and four Cheddar cheese plants. Data on condensed skim and cream is collected concurrently from plants that participate. Plants that manufacture condensed skim and cream but do not manufacture butter, NFDM, or Cheddar cheese are not included in the condensed skim and cream overview. As a result, data on condensed skim and cream is based on a lower percentage of annual production. The data from the cost studies has a practical significance beyond the boundaries of California. They are the only studies in the U.S. which present the audited and detailed processing costs of butter, NFDM, and Cheddar cheese over several years. For the plants in the study, the results can help to isolate the actual costs of manufacturing and provide benchmark figures obtained from other California manufacturing plants. Consequently, although CDFA has the legal authority to collect cost information from the various types of milk processors, the majority of plants have found the information contained in the studies valuable and have cooperated voluntarily. California Manufacturing Cost Annual - Page 3

4 Manufacturing Cost Overview Introduction The weighted average manufacturing cost of a product is a sum figure derived from the six categories of cost listed in Figure 1. To obtain a weighted average cost, each plant s manufacturing cost is weighted by its production volume relative to the production volume of all the plants included in the study. Processing labor costs are derived from plant wages, payroll taxes, and fringe benefits associated with the processing of a product. Processing non-labor includes costs such as, utilities, repairs, maintenance, supplies, depreciation, plant insurance, outside storage, and rental expenses. Packaging costs include all non-reusable items used in the packaging of a product, such as boxes, bags, tape, glue, and stretch wrap. Miscellaneous ingredient costs may include salt, color, rennet, etc. General and administrative costs include expenses incurred in the management of a plant, for example, office supplies, short-term interest, dues and subscriptions, accounting fees, headquarter expenses, office clerical wages, and executive salaries. Return on investment (ROI) allowance is an opportunity cost that represents how much interest the plant could have earned if its capital was not tied up in land, buildings, and equipment. In other words, it is viewed as an alternative source of income had the plant invested its capital elsewhere. The chart below displays the breakdown of manufacturing cost for each product by category (Figure 1). Figure 1. Manufacturing Costs by Category MANUFACTURING COSTS BY CATEGORY Butter 35% 42% 7% 9% 6% 1% NFDM 19% 59% 7% 7% 8% Cheese 27% 39% 9% 12% 11% Processing Labor Processing Non-Labor Packaging Miscellaneous Ingredients General & Admin. Return On Investment 2% California Manufacturing Cost Annual - Page 4

5 Butter Study The butter study included eight butter processing plants. The eight plants processed million pounds of butter during the period January 2011 through December 2011, representing percent of the butter processed in California. Production included both bulk and cut butter; however, published costs are for the processing of bulk butter (25 kg and 68 lb block) only. To avoid revealing plant specific information, each plant was assigned to either a low or high cost group based on its total manufacturing cost. In 2011, each cost group included four plants. Table 1 lists the weighted average cost per pound for each category of the butter manufacturing cost. Table 1. Butter Manufacturing Costs BUTTER MANUFACTURING COSTS CURRENT Study Period: January through December 2011 With Comparison to the same time period Prior Year (2010) Manufacturing cost data were collected and summarized from eight California butter plants. The eight plants processed million pounds of butter during the 12-month study period, January through December 2011, representing 99.13% of the butter processed in California. The volume total includes both bulk butter and cut butter, but the costs reflect only costs for bulk butter (25 kg and 68 lb. blocks). To obtain the weighted average, individual plant costs were weighted by their butter processing volume relative to the total volume of butter processed by all plants included in this cost study. Breakdown of Butter Manufacturing Costs - January through December 2011 Categories Low Cost Group High Cost Group Range of Costs Minimum Maximum CURRENT Weighted Average Cost All Plants Jan-Dec 2011 PRIOR YEAR Weighted Average Cost All Plants Jan-Dec 2010 Actual Difference Current Less Prior Year Dollars Per Pound of Butter Number of Plants Processing Labor $ $ $ $ $ $ $ Processing Non-Labor $ $ $ $ $ $ $ Packaging $ $ $ $ $ $ $ Misc. Ingredients $ $ $ $ $ $ $ General & Administrative $ $ $ $ $ $ $ Return on Investment $ $ $ $ $ $ $ Average Total Cost $ $ $ $ $ Volume in Group (Lbs.) 396,910, ,096, ,006, ,378,895 64,627,504 % Volume by Group 64.30% 35.70% % 100.0% -- Processing Labor: Labor costs associated with processing of product, including wages, payroll taxes and fringe benefits. Processing Non-Labor: Includes costs such as utilities, repairs and maintenance, laundry, supplies, depreciation, plant insurance, outside storage, and rent. Packaging: Includes all non-reusable items California used in Manufacturing the packaging Cost of Annual the product, - Page such 5 as boxes, bags, cartons, liners, tape, glue, and stretch wrap.

6 Butter Study Butter Manufacturing Costs Butter Processing Labor Figure 2. Butter Processing Labor Processing labor costs of $ per pound represented 35 percent of the total butter manufacturing cost. Analysis revealed packaging to be the most costly labor function performed (Figure 2). Laboratory 4% Engineering & Maintenance 14% Coldroom & Loadout 12% General Plant 27% Bulk Packaging 31% Receiving 4% Churn 8% Butter Processing Non-Labor Figure 3. Butter Processing Non-Labor Depreciation & Property Taxes 21% General Plant 30% Supplies 10% Repairs & Maintenance 12% Natural Gas 7% Electricity 14% Water & Sewage 6% Processing non-labor costs of $ per pound represented 42 percent of the total manufacturing cost. Furthermore, the combined utility costs for electricity, natural gas, water and sewage accounted for 27 percent of processing non-labor costs (Figure 3). An annual comparison of utility costs is presented below (Figure 4). BUTTER UTILITIES COMPARISON Figure 4. Butter Utilities Comparison $ $ $ $ $ $ $ Gas Electricity Water & Sewage California Manufacturing Cost Annual - Page 6

7 Figure 5. Butter Processing Labor Hourly Benefits 21% Hourly Wages 57% Hourly Taxes 7% Temporary Wages 3% Other 12% Butter Study Salaried Wages 9% Salaried Benefits 2% Salaried Taxes 1% Employer paid expenses for payroll include gross wages, fringe benefits, and payroll taxes (includes workers comp). Figure 5 provides a breakdown of plant payroll costs by percentage. Packaging costs of $ per pound represented 7 percent of the total manufacturing cost. Bulk packaging includes all non-reusable items used in the packaging of bulk butter, such as boxes, bags, cartons, liners, tape, glue, and stretch wrap. Miscellaneous ingredient costs increased 14 percent in The weighted average cost of $ per pound represented 1 percent of the total manufacturing cost. General and administrative costs of $ per pound represented 9 percent of the total manufacturing cost. Return on investment costs decreased to $ per pound but at 6 percent, represented a significant portion of the manufacturing cost. The cost of manufacturing butter decreased to $ from $ per pound the year prior. Figure 6 provides us a comparison for each cost category over a three-year period. $0.08 Figure Butter 6. Butter Manufacturing Costs Costs 2009 Comparison $0.06 $0.04 $0.02 $0.00 Miscellaneous Ingredients Packaging Processing Labor Processing Non-Labor Gen & Admin Return On Investment California Manufacturing Cost Annual - Page 7

8 Nonfat Dry Milk Study The 2011 nonfat dry milk (NFDM) study included nine plants whose combined production was million pounds, representing percent of the NFDM produced in California. Of the million pounds produced, percent was sold for human consumption, and 0.42 percent was sold as animal feed. To avoid revealing plant specific information, each plant was assigned to either a low cost group, medium cost group, or high cost group based on its total manufacturing cost. In 2011, each cost group included three plants. Table 2 lists the weighted average cost per pound for each category of the manufacturing cost. Table 2. Nonfat Dry Milk Manufacturing Costs NONFAT DRY MILK MANUFACTURING COSTS CURRENT Study Period: January through December 2011 With Comparison to the same time period Prior Year (2010) Manufacturing cost data were collected and summarized from nine California NFDM plants. The nine plants processed million pounds of NFDM during the 12-month study period, January through December 2011, representing 97.05% of the NFDM processed in California. The volume includes NFDM, both animal and human consumption. NFDM for human consumption represented 99.58% of the million pounds of NFDM processed, and NFDM for animal consumption represented 0.42%. The volume total includes all grades of NFDM packaged in any container size, but the costs reflect only costs for 25 kg and 50 lb. bags of NFDM. To obtain the weighted average, individual plant costs were weighted by their NFDM processing volume relative to the total volume of NFDM processed by all plants included in the cost study. Categories Breakdown of Nonfat Dry Milk Manufacturing Costs - January through December 2011 Low Cost Group Medium Cost Group High Cost Group Range of Costs Minimum Maximum Dollars Per Pound of NFDM CURRENT Weighted Average Cost All Plants Jan-Dec 2011 PRIOR YEAR Weighted Avg Cost All Plants Jan-Dec 2010 Number of Plants Actual Difference Current Less Prior Year Processing Labor $ $ $ $ $ $ $ $ Processing Non-Labor $ $ $ $ $ $ $ $ Packaging $ $ $ $ $ $ $ $ General & Administrative $ $ $ $ $ $ $ $ Return on Investment $ $ $ $ $ $ $ $ Average Total Cost $ $ $ $ $ $ Volume in Group (Lbs.) 304,198, ,696,236 39,279, ,174, ,039, ,865,682 % Volume by Group 41.04% 53.66% 5.30% % 100.0% -- Processing Labor: Labor costs associated with processing of product, including wages, payroll taxes and fringe benefits. Processing Non-Labor: Includes costs such as utilities, repairs and maintenance, laundry, supplies, depreciation, plant insurance, outside storage, and rent. Packaging: Includes all non-reusable items used in the packaging of the product, such as boxes, bags, cartons, liners, tape, glue and stretch wrap. General & Administrative: Includes expenses California in the management Manufacturing of Cost the Annual company, - Page such 8 as office supplies, short-term interest, dues and subscriptions, accounting fees, headquarter charges, office clerical wages and executive salaries. Return on Investment: Calculated by subtracting accumulated depreciation from the original cost of assets, with the

9 Nonfat Dry Milk Study Nonfat Dry Milk Manufacturing Costs Processing labor costs were $ per pound, 6 percent lower than in The weighted average cost for 25-kg bag packaging labor was $ per pound, representing 12 percent of processing labor costs (Figure 7). Figure 7. NFDM Processing Labor Laboratory 6% Engineering & Maintenance 15% General Plant 24% Warehouse & Loadout 11% Bag Packaging 12% Evaporator 12% Dryer 14% Receiving 6% Figure 8. NFDM Processing Non-Labor Natural Gas 23% General Plant 24% Electricity 14% Repairs & Maintenance 9% Supplies 6% Depreciation & Property Taxes 19% Water & Sewage 5% Powder Labor Processing non-labor costs of $ per pound accounted for 59 percent of the NFDM manufacturing cost. The operation of both an evaporator and a dryer adds significantly to the utility costs of a NFDM processing plant. In 2011, the utilities cost was 42 percent of processing non-labor costs (Figure 8). An annual comparison of utility costs is provided below (Figure 9). Powder Non-Labor $ POWDER UTILITIES COMPARISON Figure 9. NFDM Utilities Comparison $ $ $ $ Gas Electricity Water & Sewage California Manufacturing Cost Annual - Page 9

10 Nonfat Dry Milk Study Packaging costs of $ per pound represented 7 percent of the total NFDM manufacturing cost. Figure 10. NFDM Packaging Size Totes 36% Multi-Wall Bags 64% Sixty-four percent of the NFDM was packaged in 25-kg or 50-lb multi-wall bags; the remaining 36 percent was packaged in totes weighing between 1,100 to 3,200 lbs each (Figure 10). General and administrative costs of $ per pound accounted for 7 percent of the NFDM manufacturing cost. Powder Packaging The return on investment (ROI) allowance is calculated by subtracting accumulated depreciation from the original cost of assets. Next, the remaining book value is multiplied by the Moody s BAA corporate bond index. The resulting amount is then allocated to the products based on the same methods used to allocate the depreciation expense. In 2011, ROI costs were $ per pound. In 2011, the NFDM manufacturing cost decreased 6 percent from the prior year to $ per pound. Figure11 shows the changes that have occurred in each cost category over a three-year period. $0.12 Figure 11. Powder NFDM Manufacturing Manufacturing Costs Costs 2009 Comparison $0.10 $0.08 $0.06 $0.04 $0.02 $0.00 Packaging Processing Labor Processing Non-Labor Gen & Admin Return On Investment California Manufacturing Cost Annual - Page 10

11 Cheese Study In 2011, the cheese study included four processing plants. To avoid revealing plant specific information, the results gathered from all four plants were included in one weighted average figure for each category of 40 lb block Cheddar cheese processing cost (Table 3). Table CHEESE 3. Cheese MANUFACTURING Manufacturing COSTS Costs CURRENT Study Period: January through December 2011 With Comparison to the same time period Prior Year (2010) Manufacturing cost data were collected and summarized from four California cheese plants. Due to confidential reasons, total cheese volumes cannot be displayed. The volume total includes both Cheddar and Monterey Jack cheeses, but the costs reflect only costs for 40-lb. blocks of Cheddar. Two plants processed 500-lb. barrels or 640-lb. blocks. Packaging costs and packaging labor for 40-lb. blocks were substituted for these plants. To obtain the weighted average, individual plant costs were weighted by their cheese processing volume relative to the total volume of cheese processed by all plants included in the cost study. For all cheese: the weighted average yield was lbs. of cheese per hundredweight of milk. The weighted average moisture was 37.37% and the weighted average vat tests were 4.30% fat and 9.29% SNF. Breakdown of Cheese Manufacturing Costs - January through December 2011 Categories Total Cost One Group CURRENT Weighted Average Cost All Plants Jan-Dec 2011 PRIOR YEAR Weighted Average Cost All Plants Jan-Dec 2010 Actual Difference Current Less Prior Year Dollars Per Pound of Cheese Number of Plants Processing Labor $ $ $ $ Processing Non-Labor $ $ $ $ Packaging $ $ $ $ Misc. Ingredients $ $ $ $ General & Administrative $ $ $ $ Return on Investment $ $ $ $ Average Total Cost $ $ $ $ Volume in Group (Lbs.) 585,108,135 Processing Labor: Labor costs associated with processing of product, including wages, payroll taxes and fringe benefits. Processing Non-Labor: Includes costs such as utilities, repairs and maintenance, laundry, supplies, depreciation, plant insurance, outside storage, and rent. Packaging: Includes all non-reusable items used in the packaging of the product, such as boxes, bags, cartons, liners, tape, glue and stretch wrap. Misc. Ingredients: Includes salt, California color, and Manufacturing rennet. Cost Annual - Page 11 General & Administrative: Includes expenses in the management of the company, such as office

12 Cheese Study In addition to Cheddar and Jack cheeses, the plants processed various other types of cheese and cheese by-products. For all Cheddar cheese though, the weighted average vat yield was pounds of cheese per hundredweight (cwt) of milk, the weighted average moisture was percent, and the weighted average vat test was 4.30 percent fat and 9.29 percent solids-not-fat (Table 4). Table 4. All Cheddar Cheese Production Parameters Comparison Cheddar Cheese Production Parameters from Cost Studies Year Finished Vat Fat Vat SNF Vat Moisture % Test % Test % Yield (Lbs.) Figure 12. Cheese Dry Milk Payroll Costs Hourly Wages 53% Hourly Benefits 11% Temporary Wages 1% Hourly Taxes 6% Other 29% Salaried Wages 24% Salaried Benefits 3% Salaried Taxes 2% Employer paid expenses for payroll include gross wages, fringe benefits, and payroll taxes (includes workers comp). Figure 12 provides a breakdown of plant payroll costs by percentage. California Manufacturing Cost Annual - Page 12

13 Cheese Study Cheddar Cheese Manufacturing Costs Processing labor costs were $ per pound. For the plants that processed 500-lb barrels or 640-lb blocks, the weighted average packaging labor cost for 40-lb block Cheddar cheese was substituted. Notably, engineering and maintenance costs represented 20 percent of the processing labor cost (Figure 13). Cheese Non-Labor Figure 13. Cheese Processing Labor Cheese Making 15% 40-Lb. Packaging 19% Receiving 7% Warehouse & Loadout 10% General Plant 20% Engineering & Maintenance 20% Laboratory 9% Figure 14. Cheese Processing Non-Labor Depreciation & Property Taxes 12% Supplies 14% General Plant 31% Repairs & Maintenance 20% Natural Gas 10% Electricity 7% Water & Sewage 6% Cheese Labor Processing non-labor costs of $ per pound were 39 percent of the total manufacturing cost. Furthermore, the combined utility costs of gas, electricity, water and sewage accounted for 23 percent of processing non-labor costs (Figure 14). An annual comparison of utility costs is presented below (Figure 15). $ $ CHEESE UTILITIES COMPARISON Figure 15. Cheese Utilities Comparison Cost per per Pound $ $ $ $ $ $ $ $ Gas Electricity Water & Sewage California Manufacturing Cost Annual - Page 13

14 Cheese Study Packaging costs included all non-reusable items, such as boxes, liners, tape, glue, and stretch-wrap. The weighted average packaging cost for 40-lb block Cheddar cheese was substituted for those plants producing 500-lb barrel or 640-lb block cheese. Packaging costs were $ per pound. Miscellaneous ingredient costs for Cheddar cheese included salt, color, rennet, fortification costs, etc. The weighted average cost increased 20 percent to $ per pound from General and administrative costs of $ per pound accounted for 11 percent of the manufacturing cost. Return on investment (ROI) costs were $ per pound, a 4 percent decrease from the prior year. ROI costs represented just 2 percent of the total manufacturing cost. Overall, the cost of manufacturing cheese increased to $ per pound from the prior year. Figure 16 illustrates the changes occurring in each category of cost over a threeyear period. $0.08 Figure 16. Cheese Manufacting Costs Comparison Cheese Manufacturing Costs $0.06 $0.04 $0.02 $0.00 Miscellaneous Ingredients Packaging Processing Labor Processing Non-Labor Gen & Admin Return On Investment California Manufacturing Cost Annual - Page 14

15 Condensed Skim & Cream The manufacturing cost of bulk dairy products, such as condensed skim and cream, are not as precise as packaged products like butter, NFDM, and cheese. There are very few direct costs associated with bulk dairy products. Most, if not all, bulk dairy product costs are derived from the general plant costs allocated to them based on component hundred-weight (cwt). Homogenization is a process where the fat particulates of milk are reduced in size to make a product more uniform in consistency and taste. Prior to being homogenized though, cream and condensed skim may be separated from milk and sold as a valuable commodity or utilized to make products such as butter, powder, or cheese. Condensed Skim Overview In 2011, the condensed skim study was completed on nine plants whose combined sales were million pounds. The weighted average manufacturing cost of condensed skim decreased 6 percent from the prior year to a cost of $3.99 per cwt. (Figure 17). $2.50 Figure 17. Condensed Skim Manufacturing Costs Comparison Condensed Skim Manufacturing Cost: Cost Cost per per Hundredweight Cwt $2.00 $1.50 $1.00 $0.50 $0.00 Processing Labor Processing Non-Labor Gen & Admin Return On Investment 2009 $ $ $ $ $ $ $ $ $ $ $ $ California Manufacturing Cost Annual - Page 15

16 Cream Overview Condensed Skim & Cream In 2011, the cream study included ten plants whose combined sales were million pounds. The weighted average manufacturing cost of cream decreased 10 percent from the prior year to a cost of $4.05 per cwt. (Figure 18). $2.50 Figure Cream 18. Manufacturing Cream Manufacturing Costs: 2009 Costs - Comparison 2011 Cost per Cwt Cost per Hundredweight $2.00 $1.50 $1.00 $0.50 $0.00 Processing Labor Processing Non-Labor Gen & Admin Return On Investment 2009 $ $ $ $ $ $ $ $ $ $ $ $ California Manufacturing Cost Annual - Page 16

17 Figure 19. Simplified Flowchart of a Butter and Nonfat Dry Milk Plant Condensed Skim Totes (>1,000 lbs.) Condense Dry Nonfat Dry Milk 50 lb. Multi-Wall Bag Skim 25 kg Multi-Wall Bag Farm Milk Separate Cream & Skim Buttermilk Condensed Buttermilk Cream Condense Dry Churn Cream Bulk Cream Butter 68 lb. Box 25 kg Box Buttermilk Powder Simplified Product Flow in a Cheese Plant with By-Product Processing Print Butter Figure 20. Simplified Flowchart of a Cheese Plant with By-Product Processing Fortification Ingredients Wholesale Farm Milk Starter & Rennet 40 lb. Blocks Cut & Wrap or Shred Cheese Vat Wholesale Cheese Making Press Curds Curds 640 lb. Block Cut & Wrap or Shred Wholesale Separate Curds & Whey 500 lb. Barrels Reprocess Whey Whey cream Churn Whey Butter Separate Whey Whey Skim Reverse Osmosis Ultrafiltration Whey Protein Concentrate Lactose Water Recycled to Wash & Clean Plant Condense & Dry Whey Skim Whey Powder California Manufacturing Cost Annual - Page 17

18 Manufacturing Cost Unit Staff (pictured from left to right): Bottom Row: Jackie Juarez; Venetta Reed, Supervisor; Leticia Regalado. Second row: Raymond Greth, Stephanie Qian, Joseph Reno We welcome your comments on this Manufacturing Cost Annual. Please send your comments and suggestions to: Venetta Reed, Supervising Auditor Dairy Marketing Branch 1220 N Street Sacramento, CA California Manufacturing Cost Annual - Page 18